Microwaveable Packaged Food Product

ABSTRACT

A package containing nuts and suitable for microwave heating is described herein. The package is configured to heat the nuts and provide an aroma reminiscent of traditional, freshly-roasted nuts. The freshly-roasted nut attributes include an aroma, temperature, texture and taste, which are reproduced with the microwave package. The package preferably, though not necessarily, incorporates one or more susceptors in order to provide additional heating, such as conductive heating, to the nuts. The package also preferably includes a sufficient headspace to allow for the aromas to develop.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Nonprovisional patentapplication Ser. No. 15/636,257, filed on Jun. 28, 2017, which is herebyincorporate by reference in its entirety.

FIELD

This disclosure relates generally to microwaveable food products, andmore specifically to a packaged food product for retail sale in whichthe packaging enables enhancement or optimization of organolepticproperties of the food product contained therein during microwaveheating.

BACKGROUND

One of the challenges associated with microwave heating of certain foodproducts is the need to avoid generation of undesired aroma components,e.g., those that may result from overheating or scorching, whileachieving desired aroma notes and while warming the product generallyuniformly.

Some food products have a well-defined configuration, e.g., solid,one-piece farinaceous food products, which can help to provideconsistency and repeatability in response to exposure to microwaveenergy for a particular period of time at a particular power setting ina particular type of oven. A package of mixed, shelled nuts, on theother hand, can be subject to intra-package reconfiguration before,during and after heating, and accordingly different packages containingthe same mass of shelled nuts can react differently to the samemicrowave energy exposure. One particular problem that can occur wherenuts or nut pieces of various varieties and sizes are included in asingle package is that small pieces may be susceptible to overheating,particularly if they are disposed in “hot spots,” e.g., in contact witha susceptor, and/or at locations where microwave energy is concentratedor of a higher magnitude due to variations in field strength within amicrowave oven cavity.

Another problem is that variations in microwave field strength andconfiguration among various microwave ovens can present problems withrespect to providing a package that will perform satisfactorily in avariety of commonly used, commercially available microwave ovens.

Another problem relates to quantification of desirable aromacharacteristics. Different consumers may perceive the same aromacomponents in different ways. Thus, application of objective standardsin order to provide desirable aroma characteristics while also reducingor eliminating undesirable aroma components can be difficult.

SUMMARY

Described herein is a packaged food product comprising a measuredquantity of a food product contained within a package that optimizes orenhances organoleptic properties of the food product during microwaveheating. The food product may comprise almonds, including, e.g.,Mission, Carmel and Non-Pareil almonds, Brazil nuts, cashews includinge.g. 320 cashews, chestnuts, granola, hazelnuts, macadamia nuts, peanutsincluding e.g. Jumbo Runner peanuts and Virginia Extra Large peanuts,pecans, pistachios, pine nuts, pumpkin seeds, sunflower seeds, walnuts,among other nuts or seeds, and/or other food items. The food product mayinclude GMO ingredients, or may be free from GMO ingredients. In someembodiments, the nuts in the package are shelled nuts, i.e., nuts fromwhich shells have been removed. By one illustrative approach, the foodproduct includes shelled, roasted peanuts; shelled, mixed nuts; shelled,roasted almonds; or shelled, roasted cashews. In other embodiments, thenuts in the package may be partly or entirely unshelled, i.e., they mayinclude shells which have not been removed, or shells that have beenonly partially removed. In some embodiments, the nuts may include shellsthat have been partly opened to expose the kernels within the shells.The examples below, unless otherwise indicated, pertain to shelled nuts.

In some embodiments, the food product comprises one or more varieties ofraw or partially-roasted shelled nuts. A modified atmosphere comprising,e.g., nitrogen, carbon dioxide, and/or combinations of these or othergases may be also provided by gas flushing the package, thereby reducingthe volume of oxygen in the package. The package may be configured tocooperate with a microwave oven to heat the shelled nuts and provide anaroma reminiscent of traditional, freshly-roasted nuts, as well asadditional freshly-roasted nut attributes including temperature, textureand taste. The package, though not necessarily, incorporates one or moresusceptors to provide localized enhanced heating, such as conductiveheating, to certain components of the food product, while the entirefood product is heated as a result of exposure to microwave energy. Thepackage also may include a predetermined volume of headspace tofacilitate aroma development. In one illustrative approach, a quantityof shelled nuts is disposed in a flexible film pouch with a patterned ordiscontinuous susceptor (such as, for example a susceptor having a gridpattern) disposed on an interior thereof. Further, in one illustrativeexample, the susceptor (such as, for example, the grid-like susceptor)is disposed only partially over the interior surface such that overapproximately 60% of the susceptor is not in contact with the foodproduct in the package when heated. During the heating operation, forexample, a majority of the susceptor(s) may be disposed on a side of thepouch or package opposite the side or surface that the food productrests (or is otherwise in contact with) during the microwave heatingoperation.

In some embodiments, the package comprises a pouch formed of a flexiblefilm. The pouch may be hermetically sealed. In some embodiments, thepouch may contain a measured quantity of a food product such as shellednuts, wherein the total weight of the food product is at least 0.75 oz.,and no more than 2 oz. In some embodiments, the food product may consistof about 1.0 oz. to about 1.5 oz., or about 1 oz., of shelled nuts. Inother embodiments, the food product may include a larger quantity ofnuts weighing, e.g., about 6 oz. By one exemplary approach, ahermetically-sealed flexible film pouch, encases another film pouch(comprised of flexible film, paper, and a discontinuously disposedsusceptor), which contains the food product therein.

Where susceptors are employed, the susceptors are preferably disposedwithin the flexible film pouch, and may be incorporated into one or morewalls of the pouch or attached thereto. The packaged food product may becapable of being microwaved while sealed in a closed configuration toroast the food product to a temperature of, e.g., about 120° F. to about260° F., 150° F. to about 230° F., or 180° F. to 200° F. In someembodiments, the flexible film pouch may be capable of withstandingexpansion and/or internal pressure generated during microwave heating sothat it will remain sealed in closed configuration during heating. Inother embodiments, the pouch may be equipped with a relief valve,frangible seal, vent, or other means to limit interior pressure to adesired level within the pouch during microwave heating, and/or toenable internal pressure to decrease at a desired rate after completionof microwave heating. The flexible film pouch can include a longitudinalseal extending between end seals, and the one or more vents can includea pin hole or other small opening at a juncture between two seals.

The pouch may be expandable to accommodate increased interior volumeduring heating. Even though the pouch may be expandable in someconfigurations, the flexible pouch still may include one or more valvesor vents to permit release of some pressure.

In some embodiments wherein the food product comprises about 0.75 oz. toabout 2 oz. of mixed, shelled nuts, the time period during whichmicrowave heating of the packaged food product takes place may be, forexample, between 20 seconds and 130 seconds, between 60 seconds and 90seconds, or between 70 seconds and 80 seconds, using a 900 to 1200 Wmicrowave oven. In other embodiments, wherein the food product comprisesup to about 6 oz. of mixed, shelled nuts, the time period may be about45 to 360 seconds, or 180 to 360 seconds, again using a 900 W to 1200 Wmicrowave oven. In some embodiments, the packaging may includeinstructions that specify one or more time periods for microwaving atone or more power levels, with one or more longer time periods specifiedfor lower powered microwave ovens, and one or more shorter time periodsspecified for higher powered microwave ovens. In some embodiments, thefood product may comprise a 1 oz. package of mixed nuts comprisingalmonds, peanuts and cashews, and the instructions may specify heatingfor a time period such as 30 seconds or 40 seconds in a 1200 W microwaveoven. The quantities of almonds, peanuts and cashews may beapproximately equal or may vary, for example with each type of nutcomprising about 10% to 50% of the total, by weight. In someembodiments, the microwave heating may comprise warming pre-roastedshelled nuts, finishing roasting of partially roasted shelled nuts, orroasting of raw shelled nuts.

The pouch may be made from a flexible material such as a multilayerflexible film. Examples of layers that may be included in the flexiblematerial include a barrier layer; a printable film layer; an orientedfilm or PET layer; a sealable layer; a protective varnish; and acoefficient of friction modified layer. In some embodiments, theflexible material may include all of the above layers. In otherembodiments, the flexible material may include fewer than all of theselayers. In some embodiments, one or more of the above layers may extendover the entire area of the flexible material. In some embodiments, oneor more of the above layers may be partial or patterned layers,extending over less than the entire area of the flexible material. Insome embodiments, the pouch may include a paper layer that providesstiffness and insulation.

In some embodiments, the pouch may be a generally rectangular structurethat includes a top seal, two side seals and one or more folds, with thefold(s) in the form of a gusset, which can provide the pouch withstand-up stability. In other embodiments, the pouch may comprise agenerally rectangular structure having transverse end seals, alongitudinal seal along a top or bottom wall, and longitudinal foldsconnecting the top and bottom walls. In still other embodiments, thepackage may have a different configuration. In some embodiments, a tearnotch, area of weakness, or other means to facilitate opening of thepouch by a consumer can be provided in a seal such as a longitudinalseal, transverse seal, side seal, a top seal, or another location.

In some embodiments, headspace of the flexible film pouch can be reducedor minimized via vacuum packaging after shelled nuts are disposedtherein, thereby reducing the overall volume of the package andproviding efficiencies in connection with shipping, handling andstorage. Reduction of headspace can also be advantageous from thestandpoint of increasing the capacity of the package to accommodateexpansion of nitrogen, carbon dioxide, water vapor, and/or other gasesduring heating. In other embodiments, the package may be sealed withouttaking steps to reduce or minimize headspace.

In some embodiments, where the food product comprises shelled nuts, thevolume of shelled nuts may be less than 75% of a total internal packagevolume. In some embodiments, the volume of shelled nuts is between 20%and 40% of the total internal package volume. In some embodiments, thevolume of shelled nuts is about 30% of the total internal packagevolume. In some embodiments, the shelled nuts may be arranged in asingle layer within the package.

The susceptor(s) may comprise discrete components that are attached tothe film by adhesive bonding, heat sealing, or other means, or maycomprise a layer deposited on or in the film or otherwise provided as anintegral part of the film. In some embodiments, the susceptor(s) mayconsist of one or more metalized layers on the film. Such metalizedlayers may be treated with an acid solution that removes portions of themetalized layer, thereby forming a continuous metalized layer into apatterned susceptor. In some embodiments, the metallized portion may notbe treated with acid so that the entire layer is a susceptor. However,such a design, in some configurations, may allow too much heat to betransferred to the food product such that the food product overheats,burns, or scorches. Accordingly, in some illustrative embodiments, thesusceptor has a patterned configuration. Further, in some embodiments,the susceptor(s) may comprise one to three discrete susceptors. In someembodiments, a first wall of the pouch can have a first susceptorthereon, and a second wall of the pouch can have a second susceptorthereon spaced from the first susceptor, with care being taken to avoidcontact between the susceptors. By on approach, the one or moresusceptors are disposed such that a majority of the susceptor(s) are notin contact with the food product during the microwave heating operation.A majority of the susceptor is on a surface of the pouch opposite thesurface on which is the food product rests during microwaveheating/cooking. The susceptors can be positioned and configured to heatand brown portions of the shelled nuts and provide an aroma releasewithout excessive heating or scorching. In some embodiments, thesusceptor can be disposed in a pattern on the flexible film, spaced frompackage seals. In some embodiments, the packaged food product caninclude flavorings, which may include aroma-enhancing compositions,which may be applied to the nuts prior to placing them in the pouch,and/or otherwise placed in the package. Flavor application may comprise,e.g., soaking shelled or unshelled nuts in a liquid, spraying a liquidonto the nuts, tumbling the nuts in a drum with a particulate flavortreatment such as a powder or granular material, and/or spraying orotherwise introducing liquid and/or particulate flavor treatments intothe package after the nuts have been placed therein. Methods ofproviding flavor treatments may alternatively or additionally furtherinclude at least one of: depositing flavoring on an inside surface ofthe multi-layer flexible film that forms the film tub; sprayingflavoring into the film tube prior to forming the second seal of theflexible film pouch; and spraying flavoring onto the shelled nuts priorto depositing the shelled nuts in the flexible film pouch. The methodcan alternatively or additionally include depositing flavoring on aninside surface of the multi-layer flexible film prior to forming a filmtube, and/or spraying flavoring into a film tube prior to forming itinto a pouch, and/or other steps. As described further below, the flavorapplication is enhanced by use of the patterned susceptor that isprimarily disposed away from the food product such that it is not incontact therewith during the microwave heating operation

In some embodiments, flavorings may include without limitation one ormore natural flavors, savory or sweet seasonings or spices. Examplesinclude without limitation salt, black pepper, cinnamon, honey, sugar,peanut oil, caramel, coconut, and other liquid or dry seasonings. Theflavor treatments may include a first coating and a second coating,wherein the first coating functions to improve retention of a secondcoating. The coating can be effective to absorb and/or reflect a portionof the microwave energy to which it is exposed while also beingpermeable to another portion of the microwave energy. To enhance flavor,aroma and/or other organoleptic properties, an aromatic compound can bedisposed on an inside surface of the flexible film pouch prior topackaging the shelled nuts. Alternatively, or in addition, a sprayablearomatic compound can be sprayed into the flexible film pouch afterdepositing the shelled nuts therein. In some embodiments, the shellednuts can include one or more of whole nuts, halves, or other pieces withdimensions of about ¼″ to 1″ in length and ⅛″ to ½″ in width. Shellednuts may be pre-roasted at various roast levels and/or steam pasteurizedprior to packaging within the flexible film pouch. The shelled nuts maybe partially roasted, with final roasting being accomplished bymicrowave heating by the consumer. The shelled nuts can have a moisturelevel that decreases by 15%-25% during pre-roasting, while increasingthe composition of volatile compounds associated with a darker roast.The pre-roasted shelled nuts may optionally have undergone at least oneof a dry roast or an oil roast. In some embodiments, the shelled nuts inthe packaged food product comprise roasted or partially roasted peanutsand other nuts having a moisture level of about 1.1% to about 1.4%.Standard moisture levels for the partially roasted, shelled nuts mayrange from 2.6%-2.9% for almonds, 1.4-1.6% for peanuts, and 1.8%-2.4%for cashews. In some embodiments, savory coated nuts in the packagedfood product may have a moisture level of 1.5%-2.6%, including moisturein the coating and nuts. In some embodiments, sweet glazed nuts in thepackaged food product may have a moisture level of 1.0%-1.6%, includingmoisture in the glaze and nuts. In some embodiments, the glaze coatingmay help maintain the crunchiness of the nuts.

In some embodiments, the packaged food product can further include asealed overwrap around the flexible film forming the pouch that isremoved prior to microwaving. The overwrap can be gas flushed prior tosealing.

A method can be provided that includes wrapping a web of multi-layerflexible film into a film tube; providing at least one susceptor insidethe film tube; forming a first end seal to partially form a flexiblefilm pouch; depositing about 0.75 oz. to about 2 oz. shelled nuts in thepartially formed flexible film pouch; gas flushing the partially formedflexible film pouch to reduce oxygen therein; forming a second end sealin the flexible film pouch; wrapping the flexible film pouch in anoverwrap film thereby forming an overwrap pouch; gas flushing theoverwrap pouch to reduce oxygen in the overwrap pouch; and sealing theoverwrap pouch around the flexible film pouch. Gas flushing may comprisereplacing oxygen with nitrogen, carbon dioxide, and/or another gas ormixture of gases so that less than about 2% oxygen is present in thepouch headspace to reduce or minimize oxidation during the product shelflife. In some embodiments, where the gas flushed pouch is made of amaterial that includes an oxygen barrier, the product may have a shelflife of about one year or 365 days, whereas a similar product withoutgas flushing may have a shelf life of only about one month.

A method of using a packaged food product is also provided herein. Insome embodiments, the packaged food product may include about 1 oz. toabout 1.5 oz. of shelled nuts. In some embodiments, the packaged foodproduct may include about 1.0 oz. of shelled nuts. The packaged foodproduct may also include a heat-activated aroma-release composition. Insome embodiments, each of the shelled nuts individually has a mass ofabout 28 grams+/−5 grams to about 42 grams+/−5 grams. The shelled nutsmay be arranged in a single layer on a susceptor (or a portion thereof)within a sealed flexible package having a vent opening with a frangibleclosure, the shelled nuts comprising about 1.0% to about 2.0% moistureand having a predetermined aggregate surface area. The method mayinclude first maintaining the packaged food product at ambienttemperature and pressure; thereafter exposing the packaged food productto microwave energy for a period of about 25 seconds to about 100seconds, or a period of about 30 seconds to 70 seconds, or a period ofabout 35 to 65 seconds, to heat the shelled nuts and reduce theirmoisture content to between about 0.9% and about 1.3%, andsimultaneously vaporizing moisture within the package to expand thepackage and increase its interior pressure, wherein the increase ininterior pressure AP does not result in rupture of the package sealsexcept for the frangible closure associated with the vent opening.Preferably, heating the nuts results in a darkening of portions of theaggregate nut surface area. In some embodiments, the darkened portionsare in contact with or in close proximity to the susceptor duringheating. The darkened portions may comprise, e.g., about 10% to about25% of the aggregate nut surface area. The method may further includethereafter removing a portion of the package or otherwise opening thepackage to release a roasted-nut aroma, and in some embodiments, toprovide an open-topped container to provide hand-held access to theheated shelled nuts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a rear perspective view of a first embodiment of a microwavesusceptor package containing shelled nuts, showing a pair of end sealsand a fin seal configured to form a top panel and a bottom panel;

FIG. 2 is a plan view of a segment of a susceptor material disposed onone of the panels of the package of FIG. 1;

FIG. 3 is a front perspective view of a second embodiment of abottom-gusseted, standup microwave susceptor package containing shellednuts, showing a pair of side seals, a top portion having been removed,and showing a food product comprising shelled nuts following microwaveheating;

FIG. 4 is a schematic diagram of a process for providing a heated foodproduct, including placing a packaged food product in a microwave oven,heating the packaged food product, then removing a portion of thepackage to serve the food product;

FIG. 5 is a front elevation view of a packaged food product inaccordance with FIG. 3, empty and prior to removal of the top of thepackage, showing a peripheral seal area along the top and sides of thepackage;

FIG. 6 is a plan view of a web of film showing sealing areas and cutlines for use in forming the package of FIG. 5;

FIG. 7 is a plan view of a first alternative web of film showing sealingareas and cut lines for use in forming the package of FIG. 5, similar tothat of FIG. 6 but showing a susceptor added to the interior of whatwill be one of the panels of the package;

FIG. 8 is a plan view of a second alternative web of film showingsealing areas and cut lines for use in forming the package of FIG. 5,similar to that of FIG. 6 but showing susceptors added to the interiorof what will be both panels of the package;

FIG. 9 is a plan view of a third alternative web of film showing sealingareas and cut lines for use in forming the package of FIG. 5, similar tothat of FIG. 6 but showing one or more susceptors added to the interiorof what will be one of the panels of the package;

FIG. 10 is a graph showing comparative magnitudes of selected aromacomponents associated with shelled mixed nuts at room temperature, andafter warming with and without a susceptor;

FIG. 11 is a table showing comparative magnitudes of selected aromacomponents associated with individual varieties of shelled nuts at roomtemperature and after warming with a susceptor; and

FIGS. 12-15 illustrate examples of raw data generated using gaschromatography-mass spectroscopy to measure aroma components.

FIG. 16 provides numerical data that is illustrated graphically in FIG.10.

FIG. 17 is a table showing comparative magnitudes of selected aromacomponents associated with individual varieties of shelled nuts at roomtemperature and after warming with a susceptor.

FIG. 18 is a side elevational sectional view of the packaged foodproduct of FIG. 1.

FIG. 19 is an end sectional view of the packaged food product of FIG. 1.

FIG. 20 is a side view of a packaged food product in accordance withFIG. 3.

FIG. 21 is a front view of the packaged food product in accordance withFIG. 3.

FIG. 22 is a front view of a second embodiment of a microwave susceptorpackage containing shelled nuts.

FIG. 23 is a rear view of a second embodiment of a microwave susceptorpackage of FIG. 22, showing a pair of end seals and a fin sealconfigured to form a top panel and a bottom panel.

FIG. 24 is a top plan view of an opened microwave susceptor packagewhere at least some portion of a majority of the food product is indirect contact with the lower surface of the food package when disposedon one of its panels.

FIG. 25 is a cross sectional view of the packaged food product of FIG.22 at line 25-25 in a heating position wherein the package inflates andthe first side of the package lifts away from the food product duringheating.

FIG. 26 is a graph showing comparative magnitudes of selected aromacomponents associated with raw almonds at room temperature, and afterwarming with and without a susceptor,

FIG. 27 is a graph showing comparative magnitudes of selected aromacomponents associated with raw cashews at room temperature, and afterwarming with and without a susceptor

DETAILED DESCRIPTION

Packaged food products suitable for microwave heating are describedherein, including with reference to FIGS. 1-27.

In one embodiment, a packaged food product, shown in FIGS. 1, 18, and19, has a low profile and is configured to be microwaved on its side,i.e., in a generally horizontal position such that its length and widthare greater than its height. In this embodiment, the packaged foodproduct includes a pouch or package 10 that includes an uninterrupted,continuous bottom wall 22, pair of end seals 12, 14 and a top wall 16having a fin seal 18 extending longitudinally thereof. In someembodiments, the package 10 may include a pin hole vent 19 at a juncturebetween the fin seal 18 and one of the end seals 12, 14. If the package10 over-pressurizes during heating, some pressure may be relievedthrough the pin hole vent 19, or any other vents strategically includedin the package 10. Other types of vents may include slits, flaps, scoredregions, or weakened regions.

In some embodiments, the package 10 may be made in a high-speed, highvolume automated form-fill-seal operation in which a web of film isformed into a tube, with edges brought together to form the longitudinalfin seal 18, and with the transverse end seals 12, 14 formed atpredetermined spacing before and after loading of product and gasflushing, and with the packages 10 being separated from one another bycuts through the end seals 12, 14. The interior of the packageoptionally includes one or more susceptors 20. For example, a patternedsusceptor, or more specifically a grid-like susceptor 20 material, shownin FIG. 2, can be provided on one or both sides, i.e., on one or both ofthe top and bottom surfaces of the package so as to be positioned above,below, or both above and below the food product during heating. In someembodiments, the susceptor 20 may only cover a portion of the top orbottom of the package 10. In some embodiments, the package 10 contains alarge number of discrete food items 32, e.g., a mixture of shelled nuts,such as almonds, cashews and peanuts. In some embodiments, the fooditems 32 may be arranged where at least some portion of a majority ofthe food items is in direct contact with the lower surface of thepackage 10 when disposed on either the top wall 16 or the bottom wall22. In these embodiments, most or all of the food items 32 may also bein contact with, or at least in close proximity to, the top of thepackage 10 as well, at least initially during microwave heating. Asmicrowave heating progresses, expansion of the package 10 may lift thetop surface and an associated susceptor 20 from the food items 32, whichmay have a self-regulating effect on the heating operation to reduce oravoid overheating and/or or scorching due to variations in microwaveenergy, heating time or other parameters. Expansion of the package 10may also result in the edges of the top wall being raised from the floorof the microwave oven, and may change the arrangement of some or all ofthe food items from a single-layer configuration to a multiple-layerconfiguration in which some of the food items to overlie others, whichmay also have a self-regulating effect on the heating operation to helpreduce or avoid overheating and/or scorching. In some embodiments thatemploy a patterned susceptor, such as a grid-like pattern, the fooditems 32 that are on the edges of the susceptor may roast more quickly,possibly due to remaining in a configuration on the edge of the packagewhere at least a portion of the food items are in direct contact withsusceptor as opposed to a configuration which may occur in the middle ofthe package where some food items may not be in direct contact with thesusceptor.

In a second embodiment, shown in FIGS. 3, 5, 20 and 21, a packaged foodproduct includes a package or pouch 24 that is configured to stand upduring and/or following microwave heating. The pouch 24 can include apair of side seals 26, a top seal 28 and a bottom 30, shownschematically in FIG. 5. A top portion 34 of the pouch 24, whichencompasses the top seal 28, is configured for removal. The pouch 24 isshown after removal of the top portion 34 in FIG. 3.

As shown in the schematic diagram of FIG. 4, in some embodiments, apackaged food product such as any of the above-described packaged foodproducts can be inserted into a microwave oven, heated using microwaveenergy, then removed from the microwave oven, after which a portion ofthe package 24 may be removed, separated or otherwise opened to provideaccess to the food items 32. In some embodiments, the package 110 may beseparated and unfolded, such as in FIG. 24, where the food items 32remain on the susceptor 120 to receive any residual heat from thesusceptor 120. In this manner, the food products 32 may continue to bewarmed by the susceptor 20 while being consumed from the package 110.

In some embodiments including but not limited to those described above,the pouch 24 can be formed from a web of film 36, various examples ofwhich are shown in FIGS. 6-9. The web of film can be folded so thatregions 38 and 40 form the front and rear of the package, with seals 42and 44 being formed on the sides and top. In some embodiments, thebottom can comprise a single fold along line 46. Alternatively, agusseted bottom may be provided. A web of film 36 can be configuredwithout a susceptor, as shown in FIG. 6, or with one or more susceptors48 added prior to singulating the package 24 from the web of film 36, asshown in FIGS. 7-9. For example, a single susceptor 48 can be attachedto the web of film 36 in an area that will be an interior surface of oneof the front or rear walls of the package 24, as shown in FIG. 7.Alternatively, a pair of susceptor 48 surfaces can be provided on theweb of film 36 in areas that will be interior surfaces of the front 38and rear 40 walls of the package, as shown in FIG. 8. In anotheralternative, multiple types of susceptors 48 may be incorporated on asingle panel, as shown in FIG. 9, or on other panels, to provideincreased localized conductive heat transfer in a particular region of asusceptor 48. Optionally, the susceptor 48 surfaces can be positionedcloser to the bottom 30 of the package than the top 34 such that theywill be adjacent the food product near the bottom 30 of the package 24during microwave heating.

In a third embodiment, shown FIGS. 22-25, a packaged food productincludes a package or pouch 110 with an uninterrupted, continuous firstside 122, pair of end seals 112, 114 and a second side 116 having a finseal 118 extending longitudinally thereof. The interior of the package110 includes a patterned susceptor 120, such as, for example, agrid-like susceptor having overlapping lines. In one illustrativeconfiguration, the susceptor 120 only covers a portion of the interiorof the package 110, as seen in FIGS. 23 and 24, such that the susceptor120 does not extend to the end seals 112, 114 or the fin seal 118. Inother embodiments, the susceptor 120 may extend to the end seals 112,114, to the fin seal 118, and/or to both side seals 112, 114 and finseal 118. In some embodiments, the susceptor 120 patterns may include,for example, fuse or star, lined, circular, herringbone, chevron, Greekkey, gingham, houndstooth, quatrefoil, scale pattern, or anothergeometric pattern optimal for heating for a food product.

As indicated by instructions 132, the package 110 is heated with thefirst side 122 of package 110 facing upward in a microwave such that thefood product 32 is disposed on the second side 116 the package. In someembodiments, the food items 32 may be arranged where at least someportion of a majority of the food items is in direct contact with thesecond side 116 of the package, as seen in FIG. 25. In such anarrangement, all or most of the discrete food items may be contact withor at least in close proximity to the second side 116 of package 110during heating. Initially, most or all of the food items may also be incontact with, or at least in close proximity to, the first side 122 ofpackage 110. However, as microwave heating progresses, expansion of thepackage 110 may lift the first side 122 and a portion of the susceptor120 associated with the first side 122 lifts away from the food items,such that the susceptor 120 associated with the first side 122 is not indirect contact or touching the food items. The portion of the susceptor120 associated with the first side 122 may “shield” the food items, suchthat the portion of the susceptor 120 associated with the first side 122may absorb microwave energy but, due to a lack of direct contact withthe food items, may reduce the amount or rate of microwave energytransferred to the food items. This “shielding” effect may allow thefood items to cook more slowly and evenly. In some embodiments, thenumber of susceptors 120 “shielding” the food items may be, for example,over 20%, over 30%, over 40%, over 50%, over 55%, or over 60% of thesusceptors 120 in the package 110. In other words, if over 20% of thesusceptor 120 is “shielding” the food item(s), at least 20% of thesusceptor 120 surface area inside the package 110 does not contact thefood item(s) during heating of the food product.

Expansion of the package 110 may also result in the edges of the secondside 116 being raised from the floor of the microwave oven, and maychange the arrangement of some or all of the food items 32 from asingle-layer configuration to reconfigure a bit such that more of thefood items 32 overlap one another, which may also have a self-regulatingeffect on the heating operation to help reduce or avoid overheatingand/or scorching. As used herein, a single layer can include someoverlapping of the food products, but are disposed such that at leastsome portion of a majority of the food products are in direct contactwith the lower surface of the food package during the heating operation.In some embodiments that employ a pattern, such as, for example, agrid-like susceptor, food items 32 on the edges of the grid-likesusceptor may roast more quickly, possibly due to remaining in asingle-layer configuration as opposed to the multiple-layerconfiguration which may occur in the middle of the package.

Aroma is created during microwave heating due to a combination of theproduct and the packaging, and is released upon opening of the packagefollowing microwave heating, and/or through a vent during heating. Thearoma from the product can be generated not only by the nuts but also byadditional ingredients. Liquid coatings, dry seasonings and/or otheringredients may include heat stable components that are added to nutsprior to packaging and provide aroma upon opening of the packagefollowing microwave heating. In addition to a dry seasoning or coating,a liquid seasoning can optionally be added to the nuts either before orafter the application of a dry seasoning to increase the amount ofvolatile components released during microwave heating. One option is toalso, or instead, add aroma-contributing compounds to the packagingmaterial, such as by spraying the compounds on one or more interiorsurfaces of the package, such as in the headspace, after depositing thenuts and prior to sealing.

The blend of sizes of particulates in the coating as well as thephysical characteristics, such as high melting temperatures, can help tomoderate heating of nuts by absorbing or reflecting microwave energyand/or by shielding shelled nuts from microwave energy. This canadvantageously reduce the amount of microwave energy that is absorbed bythe interior and surface of the nut, thereby leading to increasedhomogeneity of the heating among the nuts and allowing the product toachieve an overall higher temperature without overheating individualareas of the nuts. Certain coatings may tend to increase susceptortemperature by reflecting microwave energy that would otherwise beabsorbed by shelled nuts or other edible substrates to which thecoatings are applied. This can help to provide desirable organolepticproperties such as crunchiness of the coatings and underlying shellednuts, while avoiding undesirable organoleptic properties such asundesirable softness of the shelled nuts. Other coatings may tend todecrease susceptor temperature by absorbing microwave energy.

In some embodiments, low-moisture sugar-based coatings or otherlow-moisture coatings may be preferable to higher moisture coatingsincluding those based on corn syrup from the standpoint that coatingsbased on corn syrup may tend to flow more easily when heated totemperatures of, e.g., 215° or 230° F., with portions of the coatingsundesirably liquefying and running off the underlying food items whenheated rather than remaining adhered thereto. Specific flavor notes thatmay be provided by the food products and/or coatings include but are notlimited to sweet, savory, and salty flavor notes, and combinationsthereof. Specific flavors for food products and/or coatings may includebut are not limited to, e.g., salted caramel, cinnamon almond, and sweetroasted cashew flavors. Examples of specific product formulas that maybe used in some embodiments are provided below.

Seasoned Cashew Ingredient Range (%) Cashew 92-98 Peanut oil 0.5-2.5Powdered seasoning 2-6

Sea Salt Nut Blend Ingredient Range (%) Almond 30-50 Cashew 24-44 Peanut16-36

Crunchy Salty Coating for Nut Blend Ingredient Range (%) Nut Blend 78-93Sugar  4-20 Corn Syrup 2-3 Salt 1.5-3  

Sea Salt Almond Ingredient Range (%) Almond   94-99 Peanut oil 0.5-3Salt 0.5-3

Coconut Cashew Ingredient Range (%) Cashews 60-85 Sugar 20-40 Coconut2-5 Corn syrup 2.5-5   Butter 1-2 Salt 0.5-2   Flavor 0.05-.2 

Salted Caramel Peanut Ingredient Range (%) Peanuts 60-85 Sugar 20-40Salt 0.5-2   Caramel seasoning 0.25-0.75

Cinnamon Almond Ingredient Range (%) Almonds 55-85 Sugar 20-40 Salt0.5-2   Cinnamon 0.5-3  

In some embodiments, thicker coatings can contribute to increasedcooking homogeneity. In some embodiments, coatings may have a thicknessof about 1 to 3 mm., and in some cases, may have an average thickness ofabout 1 mm.

The packaging can contribute to the aroma by providing suitable barrierlayers and a headspace for the aroma to accumulate. For example, thepouch can be a multilayered structure that contains a barrier material,such as EVOH (ethylene vinyl alcohol), AlO_(x) (aluminum oxide) orSiO_(x) (silicon oxide), that limits the migration of aroma componentsthrough the package during both shelf life and microwave heating. Thebarrier material can be provided either as part of the pouch or in outerpackaging that is removed prior to microwave heating. If more than onebarrier layer is employed, such layers may not envelop the paper layer.A configuration where the barrier layers surround the paper layer mayundesirably trap any moisture in the paper between the barrier layerswhen the package is heated. The package is preferably sealed duringmicrowave heating so that volatile compounds that provide the aroma donot leave the package until opened. It can be desirable to optimize theheadspace in the package in order to enable a more concentrated aromawhile also ensuring space for the aroma to develop.

The thickness of the paper in the packaging may also contribute to thehomogenous heating of the food product. The packaging may employ about20 lb. paper to about 40 lb. paper, about 20 lb. paper to about 35 lb.paper, about 23 lb. paper to about 35 lb. paper, about 25 lb. paper toabout 35 lb. paper, about 23 lb. paper, or about 35 lb. paper. Thedesignation of lb. for thickness of paper indicates the weight of 500sheets of that specific paper. Hence, the thicker the paper, the largerthe weight. In some embodiments, thicker paper, such as 35 lb. paper,may be used. The thicker paper may absorb more heat to help the foodproduct from burning, scorching, or overcooking. For example, as heat istransferred from the barrier layer or the susceptor lining, the thickerpaper may absorb more heat than thinner paper. However, the thickerpaper may also be more difficult to fold into a desirable configurationfor packaging.

In some embodiments, thinner paper, such as 23 lb. paper, may beemployed. By one approach, use of the thinner paper may allow for easierfolding of the package into more desired configurations, such as apackage with a top wall, a bottom wall, and a fin seal. The thinnerpaper may be sufficient to adhere to the susceptor and barrier materiallayer prior to heating. For some susceptor patterns or strengths, thethinner paper may not allow for particularly good adherence to thesusceptor and barrier material layer during heating, possibly due toless than adequate surface tension. In one illustrative embodiment, the23 lb. paper is sufficiently thick for adhering to a grid-patternedsusceptor during heating and also provides for easy folding. In someconfigurations, optimized, homogenous heating of the food product isachieved through a combination of the type of susceptor, the thicknessof the paper, and the amount of food product in contact with thesusceptors.

The temperatures achieved during microwave heating contribute to thearoma as well as to heating of the nuts. One way to use temperaturesduring microwave heating to contribute to aroma is to design the coatingand dry seasoning ingredients to maximize their dielectric propertieswhen applied to a nut to enable more quick and homogenous heating.Another way to use temperatures during microwave heating to contributeto aroma is to add one or more susceptors within the package to enablelocalized, conductive heating with the package, as suggested above. Thesusceptor can be disposed and/or more concentrated in an area of thepackage most likely to contain the nuts, e.g., the bottom portion in astand-up package. Further, as described herein, certain packageconfigurations, including those with a majority of the susceptorcentrally located, but not in direct contact with the food product areparticularly suitable for warming the food product and producing apleasant aromatic experience, without overheating and/or scorching thefood product.

In one example, the package contains about 1 to 1.5 ounces of eithercashews, almonds or shelled peanuts, or combinations thereof. Thepackage can include a susceptor to optimize heating of the nuts duringmicrowave heating. The package can optionally be gas-flushed. Thepackage can be heated in a microwave for between 30 and 60 seconds, forexample.

In some embodiments, strategically-configured susceptors are provided ina configuration that enables localized heating of certain portions ofthe mixed nuts to a higher temperature that enhances the aromacharacteristics of the product without unacceptably overheating theshelled nuts, optionally in combination with one or more coatings thatmay provide quantitative and qualitative aroma enhancements. Coatingsmay also enable positive or negative variation of the shelled nuts'thermal response to microwave heating.

The aroma data in FIGS. 10 and 11 were compiled by exposing roasted,shelled nuts to microwave energy with and without susceptors, and usinggas chromatography-mass spectroscopy to quantify increases in particulararoma components as a result of use of a particular susceptorconfiguration.

FIGS. 11 and 17 show data from roasted, shelled nuts, some includingflavor treatments, measured at room temperature and after microwaveheating with a susceptor in a package as described above. FIG. 11 shows,for example, that microwave warming of almonds resulted in about atwo-fold increase in an ethyl-pyrazine aroma component, which isassociated with a “roasted” or “nutty” aroma, an eighteen-fold increasein a diacetyl aroma component, which is associated with a “buttery”aroma, and a relatively small increase in furfural (caramel) aroma. FIG.17 provides additional data for the same microwave warming, showing thatit resulted in a two-fold increase of methyl pyrazine (roasted) aroma.

Each aroma component (furfural; 2,5 dimethyl pyrazine (associated with a“nutty” aroma); ethyl pyrazine; diacetyl; and benzaldehyde (oil ofbitter almond)) may have a threshold concentration range (i.e., minimumconcentration typically required for olfactory perception.) The aromathreshold for furfural is between about 280 parts per billion (ppb) andabout 8 parts per million (ppm). The aroma threshold for 2,5 dimethylpyrazine is between about 80 ppb and about 1.8 ppm. The aroma thresholdfor diacetyl is between about 0.3 ppb and about 15 ppb. The aromathreshold for benzaldehyde is between about 100 ppb and 4.6 ppm.

Further, food products may have a maximum availability of aromacomponents. For example, almonds may have up to 460 ppm of furfural,66.5 ppm of 2,5 dimethyl pyrazine, 3 ppm of ethyl pyrazine, and 2,934ppm of benzaldehyde. Cashews may have up to 7 ppm of furfural, 0.4 ppmof 2,5 dimethyl pyrazine, 1.6 ppm of diacetyl, and 0.24 ppm ofbenzaldehyde. In another example, pistachios may have up to 53 ppm offurfural and 93 ppm of 2,5 dimethyl pyrazine.

In some embodiments, microwave heating of a 1 oz. package of cinnamonalmonds, i.e. almonds with a cinnamon coating as described above,according to instructions provided on packaging as described above, maydesirably result in a significant increase of aroma components in theheadspace, e.g., an increase in furfural aroma by a factor of 100 to200, or more specifically a factor of 120 to 170, or a factor of about144; an increase in ethyl pyrazine aroma by a factor of 10 to 50, ormore specifically, a factor of about 31; an increase in methyl pyrazineby a factor of 15 to 100, or by a factor of about 50 to 60, or by afactor of about 56; and an increase in diacetyl aroma by a factor of 5to 200, a factor of 40 to 60, or a factor of about 50. (See FIGS. 11 and17.)

In some embodiments, microwave heating of a 1 oz. package of cashewsaccording to instructions provided on the packaging as described abovemay desirably result in a significant increase of aroma components inthe headspace, e.g., an increase in furfural aroma by a factor of 100 to250, or more specifically a factor of 150 to 200, or a factor of about167; an increase in ethyl pyrazine aroma by a factor of 50 to 200, ormore specifically, a factor of 100 to 150, or a factor of about 125; anincrease in methyl pyrazine by a factor of 25 to 80, or by a factor ofabout 50 to 60, or by a factor of about 56; and an increase in diacetylaroma by a factor of 200 to 400, a factor of 250 to 350, or a factor ofabout 289. (See FIGS. 11 and 17.)

FIGS. 10, 16, 26, and 27 illustrate differences in aroma values thatresult from using a particular susceptor package or a non-susceptorpackage in microwave heating of mixed nuts. To obtain the data used inFIGS. 26 and 27, a grid-like patterned susceptor was employed, where amajority of the susceptor did not contact the nuts during microwaveheating. Specifically, FIGS. 26 and 27 demonstrate that even withoutroasting or coating the nuts, the use of a patterned susceptor may stillincrease the desirable aroma properties over microwave heating withoutemploying a susceptor. However, pre-roasting and coating the nuts andusing a susceptor to heat the nuts additionally increases various keyaroma components.

The data in FIGS. 10, 11, 16 and 17 correspond to desirable aromaproperties of packaged food products described herein, and such packagedfood products in some embodiments may enable consumers to achieveincreases in various key aroma components similar to those describedherein, e.g., within 10%, 20%, 30%, 40% or 50% of the values in FIGS.10, 11, 16 and 17, while also providing other desirable organolepticproperties, without scorching or generating undesirable aromas.

Examples of raw data generated using gas chromatography-massspectroscopy to measure selected individual aroma components areprovided in FIGS. 12-15. The areas under the plots shown in FIGS. 12-15is the “Peak Area” represented by the y-axis in FIG. 10.

Data shown in FIGS. 12-15 was gathered by collecting gases from withinpouches containing a mixture of shelled nuts, specifically almonds,cashews and peanuts, on thermal desorption tubes before and aftermicrowaving with and without susceptors. Sampling was performed usingadhesive septas (Illinois Instrument PPL-193456). Headspace samples werecollected for 2 min using a vacuum pump pulling 50 mL/min (FIG. 1). Gasdisplaced was replaced using food grade nitrogen.

The following additional equipment was used in sampling and analysis:

Agilent Technologies 5975 Mass Spectrometer Agilent Technologies 6890NNetwork GC System Gerstel TDS3 Thermal Desorption System Gerstel TDSAThermodesorption Autosampler Envirochem Multiple Tube Conditioner

Thermal Desorption tubes; 3.8 mm Tenax-TA, 2.0 mm Carboxen 1003

Additional information on equipment and parameters used is set forthbelow: GC-MS Parameters:

Oven

Equilibration time: 1.00 minMaximum temp: 250 CInitial temp: 35 C (On)Initial time: 4.00 min

Ramps:

# Rate Final Temperature Final Time 1 3.00 82 0.00 2 6.00 210 10.00 3 0(off)Post temp: 240 CPost time: 5.00 minRun time: 51.00 min

Column: Agilent VF-WAX P/N CP9295 Back Inlet (Cis4) Mode: Solvent Vent

Initial temp: 0 C (Off)

Pressure: 8.8 psi (On)

Vent time: 0.00 minVent flow: 50.0 mL/min

Vent Pressure: 8.8 psi

Purge flow: 50.0 mL/minPurge time: 2.00 minTotal flow: 54.0 mL/minGas saver: OffGas type: Helium

Thermal Aux 2

Initial temp: 240 C (On)

Gerstel Maestro System Settings Maestro Runtime: 55.99 min GC Cool DownTime: 8.00 min Cryo Timeout: 25.00 min

1. A packaged food product comprising: a flexible film forming a pouchhaving an interior cavity formed by seals, the flexible film pouch beingsubstantially hermetically sealed; about 0.75-oz. to about 2-oz. shellednuts disposed within the interior cavity of the flexible film pouch; anda patterned susceptor disposed in the interior cavity of the flexiblefilm pouch, wherein over 60% of the patterned susceptor is not incontact with the food product when the food product is heated; whereinthe packaged food product is configured to be microwaved while sealed ina closed configuration to roast the shelled nuts to a temperature ofabout 120° F. to about 260° F.
 2. The packaged food product of claim 1wherein a weight of the shelled nuts is about 1.0 oz. to about 1.5 oz.,the flexible film pouch is expandable and capable of remaining sealed inthe closed configuration during a microwave operation lasting about 20seconds to about 130 seconds roasting the shelled nuts containedtherein, so as to enable a concentrated roasted aroma release uponsubsequent package opening, and the flexible film is a multilayeredstructure having at least one of the following layers therein: a barriermaterial; a printable film layer; an oriented film layer; a sealablelayer; a varnish, protective layer; a coefficient of friction modifiedlayer; and a partial or patterned layer of any of the above.
 3. Thepackaged food product of claim 1 wherein the pouch further includes apaper layer enabling stiffness and insulation thereof, the pouchincludes three side seals and a film fold, the flexible film pouch isgas flushed prior to sealing the shelled nuts therein to reduce oxygenpresence and provide a modified atmosphere in the flexible film pouch.4. The packaged food product of claim 1 wherein the flexible film pouchfurther includes a gusset providing stand-up pouch stability, and a tearnotch disposed in a portion of one of the seals, the tear notchfacilitating opening of the flexible film pouch from the closedconfiguration to an open configuration.
 5. The packaged food product ofclaim 1 wherein a volume of shelled nuts is less than 75% of a totalinternal package volume.
 6. The packaged food product of claim 1 whereinthe volume of shelled nuts is about 20% to about 40% of the totalinternal package volume, and wherein the shelled nuts are arranged on asingle layer within the package, and wherein the flexible film includesa metalized layer that forms the susceptor, and wherein the metalizedlayer has been treated with an acid solution to remove portions of themetalized layer forming a discontinuous metalized layer as a patternedsusceptor, and wherein the susceptor includes at least one to threediscrete susceptors.
 7. The packaged food product of claim 6 comprisinga first susceptor on a first panel wall of the pouch and a secondsusceptor on a second panel wall of the pouch, wherein the first andsecond susceptors are configured to heat and brown the shelled nuts andprovide an aroma release.
 8. The packaged food product of claim 1wherein the susceptor is disposed in a pattern on the flexible film,spaced from package seals.
 9. The packaged food product of claim 1further comprising nut flavorings comprising at least one of: salt,black pepper, cinnamon, honey, sugar, peanut oil, caramel, and coconut,and at least one of a coating and dry seasonings.
 10. The packaged foodproduct of claim 9 wherein the coating is effective to absorb and/orreflect microwave energy during exposure of the packaged food productthereto, while also being permeable to a portion of the microwaveenergy.
 11. The packaged food product of claim 1 wherein the shellednuts comprise one or more of peanuts, cashews, almonds, and other treenuts, whole, halves, or pieces with dimensions of about ¼″-1″ in lengthand ⅛″-½″ in width and have been pre-roasted and steam pasteurized priorto packaging within the flexible film pouch.
 12. The packaged foodproduct of claim 11 wherein the shelled nuts have a moisture level thatdecreases by 15%-25% during pre-roasting as compared to unroasted,shelled nuts, while increasing the composition of volatile compoundsassociated with roasting.
 13. The packaged food product of claim 12wherein the pre-roasted shelled nuts have undergone at least one of adry roast or an oil roast.
 14. The packaged food product of claim 1wherein the shelled nuts comprise peanuts having a moisture levelbetween about 1.1% to about 1.4%.
 15. The packaged food product of claim1 further comprising at least one of: an aromatic compound disposed onan inside surface of the flexible film pouch prior to packaging theshelled nuts; or a sprayable aromatic compound that is sprayed into theflexible film pouch after depositing the shelled nuts therein; wherein aheadspace of the flexible film pouch is reduced via vacuum packagingafter the shelled nuts are disposed therein, and the shelled nutsinclude at least one of almonds, cashews, or peanuts.
 16. The packagedfood product of claim 1 wherein the patterned susceptor has a grid-likeconfiguration.
 17. A packaged food product comprising: a flexible filmforming a pouch having an interior cavity formed by seals and having oneor more vents therein; about 0.75-oz. to about 2-oz. shelled nutsdisposed within the interior cavity of the flexible film pouch; apatterned susceptor disposed in the interior cavity of the flexible filmpouch, the susceptor configured to roast the shelled nuts duringmicrowaving, the shelled nuts are roasted to a temperature of about 120°F. to about 260° F.; and a sealed overwrap around the flexible filmforming the pouch that is removed prior to microwaving; wherein over 60%of the patterned susceptor is not in contact with the food product whenthe food product is heated; wherein the flexible film pouch filled withthe shelled nuts is configured to be microwaved in a closedconfiguration where the seals have not ruptured; wherein the vents limitinternal pressure within the pouch during microwave heating, and enableinternal pressure to decrease after completion of microwave heating. 18.The packaged food product of claim 17 wherein the flexible film pouchincludes a longitudinal seal extending between end seals, and the one ormore vents includes a pin hole at a juncture between the longitudinalseal and one of the end seals, and wherein the pouch and overwrap havebeen gas flushed to provide a modified atmosphere therein.
 19. Thepackaged food product of claim 17 wherein the patterned susceptor has agrid-like configuration.
 20. A method of making a packaged food productcomprising: wrapping a web of multi-layer flexible film into a filmtube; providing at least one patterned susceptor inside the film tube;forming a first end seal to partially form a flexible film pouch;depositing about 0.75 oz. to about 2 oz. shelled nuts in the partiallyformed flexible film pouch; gas flushing the partially formed flexiblefilm pouch to reduce oxygen therein; forming a second end seal in theflexible film pouch; wrapping the flexible film pouch in an overwrapfilm thereby forming an overwrap pouch; gas flushing the overwrap pouchto reduce oxygen in the overwrap pouch; and sealing the overwrap poucharound the flexible film pouch, and further comprising at least one of:depositing flavoring on an inside surface of the multi-layer flexiblefilm that forms the film tub; spraying flavoring into the film tubeprior to forming the second seal of the flexible film pouch; andspraying flavoring onto the shelled nuts prior to depositing the shellednuts in the flexible film pouch.
 21. A method of using a packaged foodproduct comprising about 1 oz. to about 1.5 oz. of shelled nuts and aheat-activated aroma-release composition, each of the shelled nutsindividually having a mass of 28 grams+/−5 grams to 42 grams+/−5 grams,the shelled nuts being arranged in a single layer on a portion of apatterned susceptor within a sealed flexible package having a ventopening with a frangible closure, the shelled nuts comprising about 1.0%to about 2.0% moisture and having a predetermined aggregate surfacearea, the method comprising: first maintaining the packaged food productat ambient temperature and pressure; thereafter exposing the packagedfood product to microwave energy in a 900 to 1200 W microwave oven for aperiod of about 45 seconds to about 100 seconds to heat the shelled nutsand reduce their moisture content to between about 0.9% and about 1.3%,and simultaneously vaporizing moisture within the package to inflate thepackage and increase its interior pressure; wherein exposing thepackaged food product includes over 60% of the patterned susceptor notcontacting with the food product; wherein heating the nuts results in adarkening of portions of the aggregate nut surface area; wherein thedarkened portions are in contact with the susceptor during heating, andcomprise about 10% to about 25% of the aggregate nut surface area;thereafter removing a portion of the package to release a roasted-nutaroma, and to provide an open-topped container to provide hand-heldaccess to the heated shelled nuts, wherein the packaged food productincludes a headspace and a flavor treatment disposed within the sealedflexible package, and wherein heating the packaged food product resultsin an increase of aroma components in the headspace.
 22. The method ofclaim 21 wherein the shelled nuts include cashews, and wherein theincrease of aroma components in the headspace comprises an increase infurfural aroma by a factor of 100 to 250; an increase in ethylpyrazinearoma by a factor of 50 to 200; and an increase in diacetyl aroma by afactor of 200 to 400.